ecolader: rapid discharger/charger series - Schulze Elektronik GmbH

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Page 28 ecolader: rapid discharger/charger series 10 Auxiliary sockets (pins on side of case) On both sides of the charger's case you will find a double row of pins for the connection of auxiliary devices [*] ecolader select only 10.1* Discharge load, left side of case The discharge load resistance is designed to allow discharge currents of more than 10 A; the internal current sink permits a maximum discharge current of no more than 10 A. The currents drawn by the external resistance vary with the voltage of the pack to be discharged. For this reason the internal discharge current sink is coupled with the external resistance for discharging. For example, it very accurately holds the total discharge current constant as battery voltage falls. The value of the external discharge resistance has been chosen to ensure that a 6-cell pack can be discharged at a constant rate of 20 A until it is completely flat. Since a fully charged 6-cell battery will cause a current of just on 20 A to flow through the external resistance, this represents the lowest discharge current for 6 cells, even if you set 12 A or 15 A. The resistance should not be less than 0.40 Ohm / 300 Watts for discharging 6 cells. The load resistance is always connected in parallel to the battery to be discharged, provided that you have set a discharge current higher than 10 A, and that a discharge program has been selected. Caution: standard commercial resistances will reach a temperature much higher than 100° C, and this presents a danger of fire or skin burns, and also of short-circuits if the resistance features exposed windings. For this reason use resistances with a case which prevents skin-contact, and which are either fitted with a cooling fan or can dissipate excess heat through a large-area ribbed heatsink (accessory). Connections: connect the 10-pin plug to the pins on the side, and connect the red banana plug to the positive socket of the akku 1 charge socket (see photo on page 22). 10.2 Flashing light output, left For connecting a 12 V / 25 W car flasher bulb to provide visual indication of a full or discharged battery. The active flasher output (and the buzzer) is switched off when you press any of the 9 buttons on the charger. Max. load up to 12 V / 21 W (approx. 2 A). Circuit-breaker: The ecolader includes an electronic circuitbreaker which interrupts the lamp current in an overload situation. To reset the circuitbreaker disconnect the cable to the flashing light, and allow the circuit-breaker to cool off. Remove the cause of the overload before re-connecting it. 10.3 Fan output, left For connecting a 12 V battery cooling fan. The output is polarised. It is connected permanently to the car battery supply, i.e. it is not switchable. Max. load 12 V / 5 W (approx. 0.4 A). The fan output is connected to the same circuit-breaker as the flasher output (see Section 9.2). 10.4 Temperature sensor, left (cal on eco+) For connecting the temperature sensor (LM335Z) supplied with the charger. 10.5* PC socket, left For connecting to the serial (COM) interface of a compatible PC via the interface cable (with 9-pin sub-D connector) supplied. If your vacant serial port on the PC has a 25-pin socket, use a 9 -> 25-pin mouse adaptor. See also Section 10: data interface. 10.6* 8-channel 12-bit A/D converter, right For selecting individual cells it is important to obtain accurate voltage information on each separate cell in a pack when it is discharged at a high rate, preferably 20 A. This is possible with the ecolader select, as it provides a means of connecting 8 measurement wires to factory-assembled packs (up to 7 cells), and of producing the high discharge current using an external load resistance. schulze elektronik gmbh • prenzlauer weg 6 • D-64331 weiterstadt • tel: 06150/1306-5, fax: 1306-99 internet: http://www.schulze-elektronik.com e-mail: mail@schulze-elektronik.com
ecolader: rapid discharger/charger series Operating instructions for software V1.04, date of issue 05 MAY 1998 Connections to saddle (“hump”) packs: An ideal method of connecting the individual measurement wires in the case of factorymade saddle packs is to use the small sockets which are designed to accept the discharge resistances for the individual cells. Alternatively you can make up a saddle pack discharge box precisely for this measurement task, by soldering a measurement cable to the pairs of contacts which are located over each cell connector. Caution: it only makes sense to use factory-assembled soldered packs for this purpose; the transfer resistances are too high for measuring individual cells. Connections to battery "sticks": If your stick packs are not fitted with discharge sockets, you can "make do" by soldering the measurement wires to pins, and slipping the pins under the heat-shrink sleeve. Single cells: Single cells should be clamped together in the form of sticks, fitting a plate (ideally consisting of woven copper cell link braid) between the cells. The measurement wires are soldered permanently to these plates. The cells can be supported in a U-shaped or V-shaped channel, for example. Even better, cut slots in a plastic tube to line up with the cell joints, fit the metal plates in the slots and press the cells together with a spring (see photos on page 30). Fitting the "sensor wires": If only one measurement wire is used between the cells to pick up the voltage, the contact from cell to cell must really be 100%, otherwise any slight contact resistance will be assumed to be cell resistance, and the measurement will be incorrect. For 4 cells you can use two wires per cell, which should be connected in the sequence shown in brackets (see page 27). Sequence of measurement wires: The order of the measurement wires should be coded using different colours, as it is essential to maintain the correct sequence, so that the PC analysis software (winsoft) can show the correct voltage for each cell in the pack. The colours of the wires are based on the colour code for electronic components which is in standard use throughout the world: schulze elektronik gmbh Page 29 (exception: wire 7). 4 cells: 0: black cell 1 - (cell 1 -) 1: brown cell 1 + (cell 1 +) 2: red cell 2 + (cell 3 -) 3: orange cell 3 + (cell 3 +) 4: yellow cell 4 + (cell 5 -) 5: green cell 5 + (cell 5 +) 6: blue cell 6 + (cell 7 -) 7: white cell 7 + (cell 7 +) 4-cell mode: cells 2, 4 and 6 absent. The black wire 0 must make very good contact with the pack as it carries the power supply to the 12-bit A/D converter. Wire No. 7 is a special case: between the black and white wires the voltage of the en-tire 7cell pack can be measured. The winsoft program assumes this to be the case. If you wish to measure batteries consisting of fewer cells, then this white wire must also be connected to the positive terminal of the last cell to transfer the overall voltage of the pack in every case. This even applies to packs of cells when you only wish to measure the overall voltage. With high-current charge processes in particular, the ecolader is not able to determine and display the exact voltage of a battery, due to the cable resistances inside and outside the charger. If you require exact voltage values, you must use the 12-Bit measurement procedure. i. e. you should connect the black measurement wire to the negative terminal of the first cell in the pack, and the white wire to the last cell in the pack. If you use the 4-point measurement method (using the cell holder shown on page 27) you may find that “cells” 2, 4, and 6 exhibit a low voltage when the pack is on charge. These values are due to the transfer resistance of the clamp connection. To ensure that all measurement results are reliable and reproducible, the voltage data is not transferred via the 8 measurement wires if more than one battery is connected to the ecolader select. To avoid error messages (Voltage > MAX) when the sensor wires are connected, it is important when discharging or charging always to connect the negative terminal of the charge cable first, followed by the positive terminal, when the sensor wires are connected. You will obtain false measurements of the last cell in the pack if the battery is measured during a charge process and not, as is usual, during a discharge. The car battery / mains PSU voltage must not exceed 12 V. schulze elektronik gmbh • prenzlauer weg 6 • D-64331 weiterstadt • tel: 06150/1306-5, fax: 1306-99 internet: http://www.schulze-elektronik.com e-mail: mail@schulze-elektronik.com
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ecolader: rapid discharger/charger series - Schulze Elektronik GmbH

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